ADLINK PCI-8154 User Manual

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PCI-8154

Advanced & Modulized 4-Axis Servo / Stepper

Motion Control Card

User’s Manual

Manual Rev. 2.00 Revision Date: February 22, 2006 Part No: 50-11146-1000

Advance Technologies; Automate the World.

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The information in this document is subject to change without prior notice in order to improve reliability , design, and function and does not represent a commitment on the part of the manufacturer.

In no event will the manufacturer be liable for direct, indirect, special, incidental, or consequential damages arising out of the use or inability to use the product or documentation, even if advised of the possibility of such damages.

This document contains proprietary information protected by copyright. All rights are reserved. No part of this manual may be reproduced by any mechanical, elec tronic, or other means in a ny form without prior written permission of the manufacturer.

Trademarks NuDAQ, NuIPC, DAQBench are registered trademarks of ADLINK

TECHNOLOGY INC. Product names mentioned herein are used for identification pur-

poses only and may be trademarks and/or registered trademarks of their respective companies.

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Getting Service from ADLINK

Customer Satisfaction is top priority for ADLINK Technology Inc. Please contact us should you require any service or assistance.

ADLINK TECHNOLOGY INC.

Web Site: http://www.adlinktech.com Sales & Service: Service@adlinktech.com TEL: +886-2-82265877 FAX: +886-2-82265717 Address: 9F, No. 166, Jian Yi Road, Chungho City,

Taipei, 235 Taiwan

Please email or FAX this completed service form for prompt and satisfactory service.

List of Tables

Table 2-1: CN3 Pin Assignments: Main Connector ................. 13

Table 2-2: K1/K2 Pin Assignments: Simultaneous Start/Stop . 15

Table 2-3: SW1 Card Index ..................................................... 16

Table 2-4: CN4 Manual Pulsar ................................................ 17

Table 4-1: Motion Interrupt Source Bit Settings ....................... 84

Table 4-2: Error Interrupt return codes .................................... 85

Table 6-1: Data type definitions ............................................. 131

List of Tables v

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List of Figures

Figure 1-1: PCI-8154 Block Diagram ........................................... 2

Figure 1-2: Flow chart for building an application ........................ 3

Figure 2-1: PCB Layout of the PCI-8154 ................................... 10

vi List of Figures

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1 Introduction

The PCI-8154 is an advanced & modulized 4-axis motion controller card with a PCI interface. It can generate high frequ ency pulses (6.55MHz) to drive stepper or servomotors. As a motion controller, it can provide 4-axis linear and circular interpolation and continu ous interpolation for continuous velocity. Also, changing position/ speed on the fly is available with a single axis operation.

Multiple PCI-8154 cards can be used in one system. Incremental encoder interfaces on all eight axes provide the ability to correct positioning errors generated by inaccurate mechanical transmissions.

The PCI-8154 is a completely new design. This carrier board has 4-axis pulse train output control channels. For additional functions, such as high-speed triggering or distributed I/O control, you can add on a daughter board based on requirement. This board has position compare function. Like the line scan application, the application needs motion controller to generate high speed triggering pulse and gain the high resolution images. In this situation, you can adopt a DB-8150 to extend the function on PCI-8154. In addition to motion control, sensors and actuators are key elements in machine automation. There typically needs to I/O to integrate the sensors and actuators in the contro ller. ADLINK also provides you another way to connect these devices: distributed I/O. Using daughter board, distributed I/O can be achieved with PCI-8154. This cost-effective configuration can reduce wiring ef fort and physical controller size.

Figure 1-1 shows the functional block diagram of the PCI-8154 card. The motion control functions include trapezoidal an d S-curve acceleration/deceleration, linear and circular interpolation between two axes and continuous motion positioning, and 13 home return modes. All these functions and complex computations are performed internally by the ASIC, thus it can save CPU loading.

The PCI-8154 also offers three user-friendly functions.

1. Card Index Setting:

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The card index value of the PCI-8154 can be set with a DIP switch to a value between 0 and 15. This is useful for machine makers if the whole control system is very huge.

2. Emergency Input

An emergency input pin can be wired to an emergency button to stop sending pulse output once activated.

3. Software’s Security Protection

To secure applications, a 16-bit value can be set in the EEPROM to prevent copying of custom programs.

Figure 1-1: PCI-8154 Block Diagram

2Introduction

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MotionCreatorPro is a Windows-based application development software package included with the PCI-8154. MotionCreatorPro is useful for debugging a motion control system during the design phase of a project. An on-screen display lists all installed axes information and I/O signal status of the PCI-8154.

Windows programming libraries are also provided for C++ compilers and Visual Basic. Sample programs are provided to illustrate the operations of the functions.

Figure 1-2 illustrates a flow chart of the recommended process in using this manual in developing an application. Refer to the related chapters for details of each step.

Figure 1-2: Flow chart for building an application

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1.1 Features

The following list summarizes the main features of the PCI- 8154 motion control system.

X 32-bit PCI bus Plug-and-Play (Universal) X 4 axes of step and direction pulse output for controlling

stepping or servomotor

X Maximum output frequency of 6.55MPPS X Pulse output options: OUT/DIR, CW/CCW, AB phase X Pulse input options: CW/CCW, AB phase x1, x2, x4 X Maximum pulse input frequency of 3.2Mhz in CW/CCW or

AB phase X1 mode (AB phase x4 can reach 6.5Mhz).

X Programmable acceleration and deceleration time for all

modes

X Trapezoidal and S-curve velocity profiles for all modes X 2 to 4 axes linear interpolation X 2 axes circular interpolation X Continuous interpolation for contour following motion X Change position and speed on the fly X 13 home return modes with auto searching X Hardware backlash compensator and vibration suppression X 2 software end-limits for each axis X 28-bit up/down counter for incremental encoder feedback X Home switch, index signal (EZ), positive, and negative end

limit switches interface on all axes

X 4-axis high speed position latch input X 4-axis position compare and trigger output X All digital input and output signals are 2500V

X Programmable interrupt sources X Simultaneous start/stop motion on multiple axes X Manual pulser input interface X Card index selection X Security protection on EERPOM

isolated

rms

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X Dedicated emergency input pin for wiring X Software supports a maximum of up to 12 PCI-8154 cards

operation in one system

X Compact PCB design X Includes MotionCreatorPro, a Microsoft Windows-based

application development software

X PCI-8154 libraries and utilities for Windows 2000/XP/Vista.

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1.2 Specifications

Applicable Motors:

X Stepping motors X AC or DC servomotors with pulse train input servo drivers

Performance:

X Number of controllable axes: 4 X Maximum pulse output frequency: 6.55MPPS, linear, trape-

zoidal, or S-Curve velocity profile drive

X Internal reference clock: 19.66MHz X 28-bit up/down counter range: 0-268, 435, 455 or –134,

217, 728 to +134, 217, 727

X Position pulse setting range (28-bit): -134, 217, 728 to

+134, 217, 728

X Pulse rate setting range (Pulse Ratio = 1: 65535):

Z 0.1 PPS to 6553.5 PPS. (Multiplier = 0.1) Z 1 PPS to 65535 PPS. (Multiplier = 1) Z 100 PPS to 6553500 PPS. (Multiplier = 100)

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I/O Signales:

X Input/Output signals for each axis X All I/O signal are optically isolated with 2500Vrms isolation

voltage

X Command pulse output pins: OUT and DIR X Incremental encoder signals input pins: EA and EB X Encoder index signal input pin: EZ X Mechanical limit/home signal input pins: ±EL, ORG X Composite pins: DI / LTC (Latch) / SD (Slow-down) / PCS

(Position Change Signal) / CLR (Clear) / EMG (Emergency Input)

X Servomotor interface I/O pins: INP, ALM, and ERC X General-purposed digital output pin: SVON, DO X General-purposed digital input pin: RDY, GDI X Pulse signal input pin: PA and PB (with Isolation) X Simultaneous Start/Stop signal: STA and STP

General Specifications

X Connectors: 100-pin SCSI-type connector X Operating Temperature: 0°C - 50°C X Storage Temperature: -20°C - 80°C X Humidity: 5 - 85%, non-condensing

Power Consumption

X Slot power supply (input): +5V DC ±5%, 900mA max X External power supply (input): +24V DC ±5%, 500mA max X External power supply (output): +5V DC ±5%, 300mA, max

PCI-8154 Dimensions (PCB size):

X 185mm(L) X 100 mm(W)

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1.3 Supported Software

1.3.1 Programming Library

Windows 2000/XP/Vista DLLs are provided for the PCI-8154. These function libraries are shipped with the board.

1.3.2 MotionCreatorPro

This Windows-based utility is used to setup cards, motors, and systems. It can also aid in debugging hardware and software problems. It allows users to set I/O logic parameters to be loaded in their own program. This product is also bundled with the card.

Refer to Chapter 5 for more details.

1.4 Available Terminal Board

ADLINK provides the servo & steppers use terminal board for easy connection. For steppers, we provide DIN-100S which is pinto-pin terminal board. For servo users, ADLINK offers DIN-814M, DIN-814M-J3A, DIN-814Y and DIN-814P-A4. The suitable servos are listed as follows:

Mitsubishi J2 Super DIN-814M

Mitsubishi J3A DIN-814M-J3A

Ya skawa Sigma II DIN-814Y

Panasonic MINAS A4 DIN-8 14P-A4

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2 Installation

This chapter describes how to install PCI-8154. Please follow these steps below:

X Check what you have (section 2.1) X Check the PCB (section 2.2) X Install the hardware (section 2.3) X Install the software driver (section 2.4) X Understanding the I/O signal connections (chapter 3) and

their operation (chapter 4)

X Understanding the connector pin assignm e nts (the rem a in-

ing sections) and wiring the connections

2.1 Package Contents

In addition to this User’s Guide, the package also includes the following items:

X PCI-8154: advanced 4-axis Servo / Stepper Motion Control

Card

X ADLINK All-in-one Compact Disc

Note: The terminal board is an optional accessory and would not

be included in PCI-8154 package.

If any of these items are missing or damaged, contact the dealer from whom you purchased the product. Save the shipping materials and carton to ship or store the product in the future.

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2.2 PCI-8154 Outline Drawing

Figure 2-1: PCB Layout of the PCI-8154

X CN3: Input / Output Signal Connector (100-pin) X K1 / K2: Simultaneous Start / Stop Connector X CN4: Manual Pulsar X SW1: DIP switch for card index selection (0-15) X JP2-JP9: Pulse output selection jumper (Line Driver / Open

Collector)

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2.3 PCI-8154 Hardware Installation

2.3.1 Hardware configuration

The PCI-8154 is fully Plug-and-Play compliant. Hence, memory allocation (I/O port locations) and IRQ channel of the PCI card are assigned by the system BIOS. The address assignment is done on a board-by-board basis for all PCI cards in the system.

2.3.2 PCI slot selection

Some computer system may hav e both PC I and ISA slots. Do not force the PCI card into a PC/AT slot. The PCI-8154 can be used in any PCI slot.

2.3.3 Installation Procedures

1. Read through this manual and setup the jumper according to your application

2. Turn off your computer. Turn off all accessories (printer, modem, monitor, etc.) connected to computer. Remove the cover from the computer.

3. Select a 32-bit PCI expansion slot. PCI slots are shorter than ISA or EISA slots and are usually white or ivory.

4. Before handling the PCI-8154, discharge any static buildup on your body by touching the metal case of the computer. Hold the edge of the card and do not touch the components.

5. Position the board into the PCI slot you have selected.

6. Secure the card in place at the rear panel of the system unit using screws removed from the slot.

2.3.4 Troubleshooting4:

If your system doesn’t boot or if you experience erratic operation with your PCI board in place, it’s most likely caused by an interrupt conflict (possibly an incorrect ISA setup). In general, the solution, once determined it is not a simple oversight, is to consult the BIOS documentation that comes with your system.

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Check the control panel of the Windows system if the card is listed by the system. If not, check the PCI settings in the BIOS or use another PCI slot.

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2.4 Software Driver Installation

1. Autorun the ADLINK All-In-One CD. Choose Driver Installation -> Motion Control -> PCI-8154.

2. Follow the procedures of the installer.

3. After setup installation is completed, rest art windows.

Note: Please download the latest software from ADLINK website if

necessary.

2.5 CN3 Pin Assignments: Main Connector

CN3 is the main connector for the motion control I/O signals.

No. Name I/O Function No. Name I/O Function

1 VDD O +5V power supply output 51 VDD O +5V power supply output 2 EXGND - Ext. power ground 52 EXGND - Ext. power ground 3 OUT0+ O Pulse signal (+) 53 OUT2+ O Pulse signal (+) 4 OUT0- O Pulse signal (-) 54 OUT2- O Pulse signal (-) 5 DIR0+ O Dir. signal (+) 55 DIR2+ O Dir. signal (+) 6 DIR0- O Dir. signal (-) 56 DIR2- O Dir. signal (-) 7 SVON0 O Servo On/Off 57 SVON2 O Servo On/Off 8 ERC0 O Dev. ctr, clr. Signal 58 ERC2 O Dev. ctr, clr. signal

9 ALM0 I Alarm signal 59 ALM2 I Alarm signal 10 INP0 I In-position signal 60 INP2 I In-position signal 11 RDY0 I Multi-purpose Input signal 61 RDY2 I Multi-purpose Input signal 12 EXGND Ext. power ground 62 EXGND Ext. power ground 13 EA0+ I Encoder A-phase (+) 63 EA2+ I Encoder A-phase (+) 14 EA0- I Encoder A-phase (-) 64 EA2- I Encoder A-phase (-) 15 EB0+ I Encoder B-phase (+) 65 EB2+ I Encoder B-phase (+) 16 EB0- I Encoder B-phase (-) 66 EB2- I Encoder B-phase (-) 17 EZ0+ I Encoder Z-phase (+) 67 EZ2+ I Encoder Z-phase (+) 18 EZ0- I Encoder Z-phase (-) 68 EZ2- I Encoder Z-phase (-) 19 VDD O +5V power supply output 69 VDD O +5V power supply output 20 EXGND - Ext. power ground 70 EXGND - Ext. power ground 21 OUT1+ O Pulse signal (+) 71 OUT3+ O Pulse signal (+) 22 OUT1- O Pulse signal (-) 72 OUT3- O Pulse signal (-) 23 DIR1+ O Dir. signal (+) 73 DIR3+ O Dir. signal (+) 24 DIR1- O Dir. signal (-) 74 DIR3- O Dir. signal (-)

Table 2-1: CN3 Pin Assignments: Main Connector

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No. Name I/O Function No. Name I/O Function

25 SVON1 O Servo On/Off 75 SVON3 O Servo On/Off 26 ERC1 O Dev. ctr, clr. Signal 76 ERC3 O Dev. ctr, clr. signal 27 ALM1 I Alarm signal 77 ALM3 I Alarm signal 28 INP1 I In-position signal 78 INP3 I In-position signal 29 RDY1 I Multi-purpose Input signal 79 RDY3 I Multi-purpose Input signal 30 EXGND Ext. power ground 80 EXGND Ext. power ground 31 EA1+ I Encoder A-phase (+) 81 EA3+ I Encoder A-phase (+) 32 EA1- I Encoder A-phase (-) 82 EA3- I Encoder A-phase (-) 33 EB1+ I Encoder B-phase (+) 83 EB3+ I Encoder B-phase (+) 34 EB1- I Encoder B-phase (-) 84 EB3- I Encoder B-phase (-) 35 EZ1+ I Encoder Z-phase (+) 85 EZ3+ I Encoder Z-phase (+) 36 EZ1- I Encoder Z-phase (-) 86 EZ3- I Encoder Z-phase (-) 37 PEL0 I End limit signal (+) 87 PEL2 I End limit signal (+) 38 MEL0 I End limit signal (-) 88 MEL2 I End limit signal (-) 39 GDI0 I DI/LTC/PCS/SD/CLR0 89 GDI2 I DI/LTC/PCS/SD/CLR2 40 DO0 O General Output 0 90 DO2 O General Output 2 41 ORG0 I Origin signal 91 ORG2 I Origin signal 42 EXGND Ext. power ground 92 EXGND Ext. power ground 43 PEL1 I End limit signal (+) 93 PEL3 I End limit signal (+) 44 MEL1 I End limit signal (-) 94 MEL3 I End limit signal (-) 45 GDI1 I DI/LTC/PCS/SD/CLR1/EMG 95 GDI3 I DI/LTC/PCS/SD/CLR3 46 DO1 O General Output 1 96 DO3 O General Output 3 47 ORG1 I Origin signal 97 ORG3 I Origin signal 48 EXGND - Ext. power ground 98 EXGND - Ext. power ground 49 EXGND - Ext. power ground 99 E_24V - Isolation power Input, +24V 50 EXGND - Ext. power ground 100 E_24V - Isolation power Input, +24V

Table 2-1: CN3 Pin Assignments: Main Connector

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2.6 K1/K2 Pin Assignments: Simultaneous Start/ Stop

K1 and K2 are for simultaneous st ar t/stop signals for mu ltiple axes or multiple cards.

No. Name Function

1 +5V PCI Bus power Output (VCC) 2 S TA Simultaneous start signal input/output 3 STP Simultaneous stop signal input/output 4 GND PCI Bus power ground

T able 2-2: K1/K2 Pin Assignments: Simultaneous Start/Stop

Note: +5V and GND pins are provided by the PCI Bus power.

2.7 JP2 to JP9 Jumper Setting for Pulse Output

JP2-JP9 are used to set the type of pulse output signals (DIR and OUT). The output signal type can either be differential line driver or open collector output. Refer to section 3.1 for detail jumper settings. The default setting is differential line driver mode. The mapping table is as follows:

JP6 & JP7 Axis 0 JP4 & JP5 Axis 1 JP8 & JP9 Axis 2 JP2 & JP3 Axis 3

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2.8 SW1 Card Index Selection

The SW1 switch is used to set the card index. For example, if 1 is set to ON and the others are OFF, that card index is 1. The index value can be from 0 to 15. Refer to the following table for details.

Card ID Switch Sett ing (ON=1)

00000 10001 20010 30011 40100 50101 60110 70111 81000

91001 10 1010 11 1011 12 1100 13 1101 14 1110 15 1111

T able 2-3: SW1 Card Index

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2.9 CN4 Manual Pulsar

The signals on CN4 are for manual pulsar input.

No. Name Function (Axis)

1 VDD Isolated Power +5V 2 PA+ Pulser A+ pha se signal input 3 PA- Pulser A-phase signal input 4 PB+ Pulser B+ phase signal input 5 PB- Pulser B-phase signal input 6 EXGND External Ground 7 N/A Not Available 8 N/A Not Available 9 N/A Not Available

T able 2-4: CN4 Manual Pulsar

Note: The +5V and GND pins are directly given by the PCI-bus

power. Therefore, these signals are not isolated.

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18 Installation

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3 Signal Connections

Signal connections of all I/O’s are described in this chapter. Refer to the contents of this chapter before wiring a ny cable between the PCI-8154 and any motor driver.

This chapter contains the following sections: Section 3.1 Pulse Output Signals OUT and DIR

Section 3.2 Encoder Feedback Signals EA, EB and EZ Section 3.3 Orig in Sign al ORG Section 3.4 End- Lim it Signa ls PEL an d MEL Section 3.5 In-position signals INP Section 3.6 Alarm sign al ALM Section 3.7 Devia tio n coun te r clea r signal ERC Section 3.8 general-purpose signals SVON Section 3.9 Gen e ra l-p ur po se s ign al RDY Section 3.10 Multifunction output pin: DO/CMP Section 3.11 Multifunction input signal DI/LTC/SD/PCS/CLR/EMG Section 3.12 Pulse input signals PA and PB Section 3.13 Simultaneous start/stop signals STA and STP

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3.1 Pulse Output Signals OUT and DIR

There are 4 axes pulse output signals on the PCI-8154. For each axis, two pairs of OUT and DIR differential signals are used to transmit the pulse train and indicate the direction. The OUT and DIR signals can also be programmed as CW and CCW signal pairs. Refer to section 4.1.1 for details of the logical characteristics of the OUT and DIR signals. In this section, the electrical charac teristics of the OUT and DIR signals are detailed. Each signal consists of a pair of differential signals. For example, OUT0 consists of OUT0+ and OUT0- signals. The following table shows all pulse output signals on CN3.

CN3 Pin No. Signal Name Description Axis #

3 OUT0+ Pulse signals (+) 0 4 OUT0- Pulse signals (-) 0 5 DIR0+ Direction signal (+) 0

6 DIR0- Direction signal (-) 0 21 OUT1+ Pulse signals (+) 1 22 OUT1- Pulse signals (-) 1 23 DIR1+ Direction signal (+) 1 24 DIR1- Direction signal (-) 1 53 OUT2+ Pulse signals (+) 2 54 OUT2- Pulse signals (-) 2 55 DIR2+ Direction signal (+) 2 56 DIR2- Direction signal (-) 2 71 OUT3+ Pulse signals (+) 3 72 OUT3- Pulse signals (-) 3 73 DIR3+ Direction signal (+) 3 74 DIR3- Direction signal (-) 3

The output of the OUT or DIR signals can be configured by jumpers as either differential line driver s or open collector outp ut. Users

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can select the output mode either by jumper wiring between 1 and 2 or 2 and 3 of jumpers JP2-JP9 as follows:

For differential line driver

Output Signal

OUT0+ JP6 JP6

DIR0+ JP7 JP7

OUT1+ JP4 JP4

DIR1+ JP5 JP5

OUT2+ JP9 JP9

DIR2+ JP8 JP8

OUT3+ JP3 JP3

DIR3+ JP2 JP2

output, close breaks

between 1 and 2 of:

For open collector out-

put, close breaks

between 2 and 3 of:

The default setting of OUT and DIR is set to differential line driver mode.

The following wiring diagram is for OUT and DIR signals of axis. PCI-8154:

NOTE: If the pulse output is set to open collector output mode, OUT- and DIR- are used to transmit OUT and DIR signals. The sink current must not exceed 20mA on the OUT- and DIR- pins. The default setting is 1-2 shorted.

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Suggest Usage: Jumper 2-3 shorted and connect OUT-/DIR- to a 470 ohm pulse input interface’s COM of driver. See the following figure. Choose OUT-/DIR- to connect to driver’s OUT/DIR.

Warning: The sink current must not exceed 20mA or the 26LS31

will be damaged!

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3.2 Encoder Feedback Signals EA, EB and EZ

The encoder feedback signals include EA, EB, and EZ. Every axis has six pins for three differential pairs of phase-A (EA), phase-B (EB), and index (EZ) inputs. EA and EB are used for position counting, and EZ is used for zero position indexing. Its relative signal names, pin numbers, and axis numbers are shown in the following tables:

CN3 Pin No Signal Name Axis # CN3 Pin No Signal Name Axis #

13 EA0+ 0 14 EA0- 0 15 EB0+ 0 16 EB0- 0 31 EA1+ 1 32 EA1- 1 33 EB1+ 1 34 EB1- 1 63 EA2+ 2 64 EA2- 2 65 EB2+ 2 66 EB2- 2 81 EA3+ 3 82 EA3- 3 83 EB3+ 3 84 EB3- 3

CN3 Pin No Signal Name Axis # CN3 Pin No Signal Name Axis #

17 EZ0+ 0 18 EZ0- 0 35 EZ1+ 1 36 EZ1- 1 67 EZ2+ 2 68 EZ2- 2 85 EZ3+ 3 86 EZ3- 3

The input circuit of the EA, EB, and EZ signals is shown as follows:

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Please note that the voltage across each differential pair of encoder input signals (EA+, EA-), (EB+, EB-), and (EZ+, EZ-) should be at least 3.5V. Therefore, the output current must be observed when connecting to the encoder feedback or motor driver feedback as not to over drive the source. The differential signal pairs are converted to digital signals EA, EB, and EZ; then feed to the motion control ASIC.

Below are examples of connecting the input signals with an external circuit. The input circuit can be connected to an encoder or motor driver if it is equipped with: (1) a differential line driver or (2) an open collector output.

Connection to Line Driver Output

To drive the PCI-8154 encoder input, the driver output must provide at least 3.5V across the differential pairs with at least 8mA driving capacity. The grounds of both sides must be tied together. The maximum frequency is 3Mhz or more depends on wiring distance and signal conditioning.

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Connection to Open Collector Output

To connect with an open collector output, an external power supply is necessary. Some motor drivers can provide the power source. The connection between the PCI-8154, encoder, and the power supply is shown in the diagram below . Note that an external current limiting resistor R is necessary to protect the PCI-8154 input circuit. The following table lists the suggested resistor values according to the encoder power supply.

Encoder Power (V) External Resistor R

= 8mA

+5V +12V +24V

Ω (None)

1.5kΩ

3.0kΩ

For more operation information on the encoder feedback signals, refer to section 4.4.

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3.3 Origin Signal ORG

The origin signals (ORG0-ORG3) are used as input signals for the origin of the mechanism. The following table lists signal names, pin numbers, and axis numbers:

CN3 Pin No Signal Name Axis #

41 ORG0 0 47 ORG1 1 91 ORG2 2 97 ORG3 3

The input circuit of the ORG signals is shown below. Usually, a limit switch is used to indicate the origin on one axis. The specifications of the limit switch should have contact capacity of +24V @ 6mA minimum. An internal filter circuit is used to filter out any high frequency spikes, which may cause errors in the operation.

When the motion controller is operated in the home return mode, the ORG signal is used to inhibit the control output signals (OUT and DIR). For detailed operations of the ORG signal, refer to section 4.3.3.

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3.4 End-Limit Signals PEL and MEL

There are two end-limit signals PEL and MEL for each axis. PEL indicates the end limit signal is in the plus direction and ME L indicates the end limit signal is in the minus direction. The signal names, pin numbers, and axis numbers are shown in the table below:

CN3 Pin No Signal Name Axis # CN3 Pin No Signal Name Axis #

37 PEL0 0 38 MEL0 0 43 PEL1 1 44 MEL1 1 87 PEL2 2 88 MEL2 2 93 PEL3 3 94 MEL3 3

A circuit diagram is shown in the diagram below. The external limit switch should have a contact capacity of +24V @ 8mA minimum. Either ‘A-type’ (normal open) contact or ‘B- type’ (normal closed) contact switches can be used. To set the active logic of the external limit signal, please refer to the explanation of _8154_set_limit_logic function.

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3.5 In-position Signal INP

The in-position signal INP from a servo motor driver indicates its deviation error. If there is no deviation error then the servo’s position indicates zero. The signal names, pin numbers, and axis numbers are shown in the table below:

CN3 Pin No Signal Name Axis #

10 INP0 0 28 INP1 1 60 INP2 2 78 INP3 3

The input circuit of the INP signals is shown in the diagram below:

The in-position signal is usually generated by the servomotor driver and is ordinarily an open collector output signal. An external circuit must provide at least 8mA current sink capabilities to drive the INP signal.

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3.6 Alarm Signal ALM

The alarm signal ALM is used to indicate the ala rm status from the servo driver. The signal names, pin numbers, and axis numbers are shown in the table below:

CN3 Pin No Signal Name Axis #

9ALM00 27 ALM1 1 59 ALM2 2 77 ALM3 3

The input alarm circuit is shown below. The ALM signal usually is generated by the servomotor driver and is ordinarily an open collector output signal. An external circuit must provide at least 8mA current sink capabilities to drive the ALM signal.

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3.7 Deviation Counter Clear Signal ERC

The deviation counter clear signal (ERC) is active in the following 4 situations:

1. Home return is complete

2. End-limit switch is active

3. An alarm signal stops OUT and DIR signals

4. An emergency stop command is issued by software (operator)

The signal names, pin numbers, and axis numbers are shown in the table below:

CN3 Pin No Signal Name Axis #

8 ERC0 0 26 ERC1 1 58 ERC2 2 76 ERC3 3

The ERC signal is used to clear the deviation counter of the se rvomotor driver. The ERC output circuit is an open collector with a maximum of 35V at 50mA driving capacity.

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3.8 General-purpose Signal SVON

The SVON signal can be used as a servomotor-on control or general purpose output signal. The signal names, pin numbers, and its axis numbers are shown in the following table:

CN3 Pin No Signal Name Axis #

7SVON00 25 SVON1 1 57 SVON2 2 75 SVON3 3

The output circuit for the SVON signal is shown below:

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3.9 General-purpose Signal RDY

The RDY signals can be used as motor driver ready input or general purpose input signals. The signal names, pin numbers, and axis numbers are shown in the following table:

CN3 Pin No Signal Name Axis #

11 RDY0 0 29 RDY1 1 61 RDY2 2 79 RDY3 3

The input circuit of RDY signal is shown in the following diagram:

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3.10 Multi-Functional output pin: DO/CMP

The PCI-8154 provides 4 multi-functional output channels: DO0/ CMP0 to DO3/CMP3 corresponds to 4 axes. Each of the output pins can be configured as Digit Output (DO) or as Comparison Output (CMP) individually. When configured as a Comparison Output pin, the pin will generate a pulse signal when the encoder counter matches a pre-set value set by the user.

The multi-functional channels are located on CN3. The signal names, pin numbers, and axis numbers are shown below:

CN3 Pin No Signal Name Axis #

40 DO/CMP0 0 46 DO/CMP1 1 90 DO/CMP2 2 96 DO/CMP3 3

The following wiring diagram is of the CMP on the first 2 axes:

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3.11 Multi-Functional input pin: DI/LTC/SD/PCS/CLR/ EMG

The PCI-8154 provides 4 multi-functional input pins. Each of the 4 pins can be configured as DI (Digit Input) or LTC (Latch) or SD (Slow down) or PCS (Target position override) or CLR (Counter clear) or EMG (Emergency). To select the pin function, please refer to 6.12.

The multi-functional input pins are on CN3. The signal names, pin numbers, and axis numbers are shown in the following table:

CN3 Pin No Signal Name Axis #

39 DI/LTC/SD/PCS/CLR/EMG_0 0 45 DI/LTC/SD/PCS/CLR/EMG_1 1 89 DI/LTC/SD/PCS/CLR/EMG_2 2 95 DI/LTC/SD/PCS/CLR/EMG_3 3

The multi-functional input pin wiring diagram is as follows:

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3.12 Pulser Input Signals PA and PB (PCI-8154)

The PCI-8154 can accept differential pulser input signals through the pins of CN4 listed below. The pulser behaves like an encoder. The A-B phase signals generate the positio ning info rmation, wh ich guides the motor.

CN4 Pin No Signal Name Axis # CN4 Pin No Signal Name Axis #

2PA+0-33PA-0-3 4 PB+ 0-3 5 PB- 0-3

The pulser signals are used for Axis 0 to Axis 3. User can decide to enable or disable each axis pulser with _8154_disable_pulser_input function.

The wiring diagram of the differential pulser input pins are as followed.

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3.13 Simultaneously Start/Stop Signals STA and STP

The PCI-8154 provides STA and STP signals, which enable simultaneous start/stop of motions on multiple axes. The STA and STP signals are on K1/K2.

The STP and STA signals are both input and output signals. To operate the start and stop action simultaneously, both software control and external control are needed. With software control, the signals can be generated from any one of the PCI-8154. Users can also use an external open collector or switch to drive the STA/ STP signals for simultaneous start/stop.

If there are two or more PCI-8154 cards, connect the K2 conne ctor on the previous card to K1 connector on the following card. The K1 and K2 connectors on a same PCI-8154 are connected internally.

You can also use external start and stop signals to issue a crosscard simultaneous motor operation. Just connect external start

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and stop signals to STA and STP pins on the K1 connector of the first PCI-8154 card.

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4 Operation Theory

This chapter describes the detail operation of the motion controller card. Contents of the following sections are as follows:

Section 4.1: Classifications of Motion Controller Section 4.2: Motion Control Modes Section 4.3: M ot or Drive r Int er face Section 4.4: M ec ha n ical switch Interface Section 4.5: T he Cou n ter s Section 4.6: The Comparators Section 4.7: Other Motion Functions Section 4.8: Interrupt Control Section 4.9: Multiple Cards Operation

4.1 Classifications of Motion Controller

When motor/stepper control first started, motion control was widely discussed instead of motor control. Motor control was separated into two layers: motor control and motion control. Motor control relates to PWM, power stage, closed loop, hall sensors, vector space, etc. Motion control relates to speed profile generating, trajectory following, multi-axes synchronizat ion , an d co ordin a ting .

4.1.1 Voltage motion control interface

The interfaces between motion and motor control are changing rapidly. Early on, a voltage singal was used as a command to the motor controller. The amplitude of the signal means how fast a motor is rotating and the time duration of the voltage changes means how fast a motor acceleration from one speed to the other speed. Voltage signal as a command to motor driver is so called “analog” motion controller. It is much eaiser to integrate into an analog circuit of motor controller; however noise is sometimes a big problem for this type of motion control. Also, to do positioning control of a motor, the analog motion controller must ha ve a feedback signal with position information and use a closed loop control algorithm to make it possible. This increased the complexity of motion control and not easy to use for a beginner.

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4.1.2 Pulse motion control interface

The second interface of motion and motor control is a pulse train type. As a trend of digital world, pulse trains represent a new concept to motion control. The counts of pulses show how many ste ps of a motor rotates and the frequency of pulses show how fast a motor runs. The time duration of frequency changes represent the acceleration rate of a motor. Because of this interface, a servo or stepper motor can be easier than an analog type for positioning applications. It means that motion and motor control can be separated more easily by this way.

Both of these two interfaces need to provide for gains tuning. For analog position controllers, the control loops are built inside and users must tune the gain from the controller. For pulse type position controllers, the control loops are built outside on the motor drivers and users must tune the gains on drivers.

For more than one axes’ operation, motion control seems more important than motor control. In industial applications, reliable is a very important factor. Motor driver vendors make good performance products and a motion controller vendors make powerful and variety motion software. Integrated two products make our machine go into perfect.

4.1.3 Network motion control interface

Recently, there was a new control interface was introduced--a network motion controller. The command between motor driver and motion controller is not analog or pulses signal any more. It is a network packet which contents position information and motor information. This type of controller is more reliable because it is digitized and packetized. Because a motion controller must be real-time, the nerowrk must have real-time capacity around a cycle time below 1 mini-second. This means that non-commercial networks cannot do this job. It must have a specific network, such as Mitsubishi SSCNET. The network may also be built with fiberoptics to increase communication reliability.

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4.1.4 Software real-time motion control kernel

For motion control kernel, there are three ways to accomplish it: DSP, ASIC, and software real-time.

A motion control system needs an absolutely real-time control cycle and the calculation on controller must provide a control data at the same cycle. If not, the motor will not run smoothly. Many machine makers will use PC’s computing power to do this. A feedback counter card can simply be used and a voltage output or pulse output card to make it. This method is very low-end and takes much software effort. For sure their realtime performance, they will use a real-time software on the system. It increases the complexity of the system too. But this method is the most flexible way for a professional motion control designers. Most of these methods are on NC machines.

4.1.5 DSP motion control kernel

A DSP-based motion controller kernel solves real-time software problem on computer. DSP is a micro-processer itself and all motion control calculations can be done on it. There is no real-time software problem because DSP has its own OS to arrange all the procedures. There is no interruption from other inputs or context switching problem like Windows based computer. Although it has such a perfect performance on real-time requirements, its calculation speed is not as fast as PC’s CPU at this age. The software interfacing between DSP controller’s vendors and users is not easy to use. Some controller vendors provide some kind of assembly languages for users to learn and some controller vendors provide only a handshake documents for users to use. Both ways are not easy to use. DSP based controller provide a bette r way than software kernel for machine makers to build they applications.

4.1.6 ASIC motion control kernel

An ASIC motion control kernel is falls between software kernel and DSP kernel in terms of difficulty. It has no real-time problem because all motion functions are done via the ASIC. Users or controller’s vendors just need to set some parameters which the ASIC requires and the motion control will be done easily. This kind of

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motion control separates all system integration problems into 4 parts: Motor driver’s performance, ASIC outputting profile, vendor’s software parameters to the ASIC, and users’ command to vendors’ software. It makes motion controller co-operated more smoothly between devices.

4.1.7 Compare Table of all motion control types

Software ASIC DSP

Price Fair Cheap Expensive

Functionality Highest Low Normal

Maintenance Hard Easy Fair

Analog Pulses Network

Price High Low Normal

Signal Quality Fair Good Reliable

Maintenance Hard Easy Easy

4.1.8 PCI-8154 motion controller type

The PCI-8154 is ASIC based, pulse type motion controller made into three blocks: motion ASIC, PCI card, software motion library. The motion ASIC can be accessed via our software motion libra y under many kinds of Windows NT/2000/XP, Linux, and RTX driver. Our software motion library provides one-stop-function for controlling motors. All the speed parameter calculations are done via our library.

For example, to perform a one-axis point to point moition with a trapezoidal speed profile, only fill the target position, speed, and acceleration time in one function. Then the motor will run as the profile. It takes no CPU resources because every control cycle pulse generation is done by the ASIC. The precision of target position depends on motor drivers’ closed loop control performance and mechnical parts, not on motion controller’s command because the motion controller is only responsible for sending correct pulses counts via a desired speed profile. So it is much e asier for programmers, mechnical or electrical engineers to find out problems.

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4.2 Motion Control Modes

Motion control makes the motors run according to a specific speed profile, path trajectory and synchronous condition with other axes. The following sections describe the motion control modes of this motion controller could be performed.

4.2.1 Coordinate system

The Cartesian coordinate is used and pulses are in the unit of length. The physical length depends on mechanical parts and motor’s resolution. For example, if a motor is on a screw ball, and the pitch of screw ball is 10mm and the pulses needed for a round of motor are 10,000 pulses. One pulse’s physical unit is equal to 10mm/10,000p =1 mm.

Just set a command with 15,000 pulses for motion controller if we want to move 15mm. How about if we want to move 15.0001mm?

Simple! The motion controller will keep the residue value less than 1 pulse and add it to next command.

The motion controller sends incremental pulses to motor drive rs. It means that we can only send relative command to motor driver. But we can solve this problem by calculating the difference between current position and target position first. Then send the differences to motor driver. For example, if current position is 1000 and we want to move a motor to 9000, you can use an absolute command to set a target position of 9000. Inside the motion controller, it will get current position 1000 first then calculate the difference from target position. The result is +8000. So, the motion controller will send 8000 pulses to motor driver to move the position of 9000.

Sometimes, users need to install a linear scale or external encoder to check machine’s position. But how do you to build this coordinate system? If the resolution of external encoder is 10,000

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pulses per 1mm and the motor will move 1mm if the motion controller send 1,000 pulses, It means that when we want to move 1 mm, we need to send 1,000 pulses to motor driver then we will get the encoder feedback value of 10,000 pulses. If we want to use an absolute command to move a motor to 10,000 pulses position and current position read from encoder is 3500 pulses, how many pulses will it send to motor driver? The answer is (10000 – 3500 ) / (10,000 / 1,000)=650 pulses. The motion controller will calculate it automatically if users set “move ratio” already. The “move ratio” means the (feedback resolution/command resolution).

4.2.2 Absolute and relative position move

In the coordinate system, we have two kinds command for users to locate the target position. One is absolute and the other is relative. Absolute command means that user give the motion controller a position, then the motion controller will move a motor to that position from current position. Relative command means that user give the motion controller a distance, then the motion controller will move motor by the distance from current position. During the movement, users can specify the speed profile. It means user can define how fast and at what speed to reach the position.

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4.2.3 Trapezoidal speed profile

Trapezodial speed profile means the acceleration/deceleration area follows a 1st order linear velocity profile (constant acceleration rate). The profile chart is shown as below:

The area of the velocity profile represents the distance of this motion. Sometimes, the profile looks like a triangle because the desired distance from user is smaller than the area of given speed parameters. When this situation happens, the motion controller will lower the maximum velocity but keep the acceleration rate to meet user’s distane requirement. The chart of this situation is shown as below:

This kind of speed profile could be applied on velocity mode, position mode in one axis or multi-axes linear interpolation and two axes circular interpolation modes.

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4.2.4 S-curve and Bell-curve speed profile

S-curve means the speed profile in accelerate/decelerate area follows a 2nd order curve. It ca n reduce vibration at the beginning of motor start and stop. In order to speed up the acceleration/deceleration during motion, we need to insert a linear part into these areas. We call this shape as “Bell” curve. It adds a linear curve between the upper side of s-curve and lower side of s-curve. This shape improves the speed of acceleration and also reduces the vibration of acceleration.

For a bell curve, we define its shape parameters as below:

X Tacc: Acceleration time in second X Tdec: Deceleration time in second X StrVel: Starting velocity in PPS X MaxVel: Maximum velocity in PPS X VSacc: S-curve part of a bell curve in deceleration in PPS X VSdec: S-curve part of a bell curve in deceleration in PPS

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If VSacc or VSdec=0, it means acceleration or deceleration use pure S-curve without linear part. The Acceleration chart of bell curve is shown below:

The S-curve profile motion functions are designed to always produce smooth motion. If the time for acceleration parameters combined with the final position don’t allow an axis to reach the maximum velocity (i.e. the mov ing distance is too small to reach MaxVel), then the maximum velocity is automatically lowered (see the following Figure).

The rule is to lower the value of MaxVel and the Tacc, Tdec, VSacc, VSdec automatically, and keep StrVel, acceleration, and jerk unchanged. This is also applicable to Trapezoidal profile motion.

This kind of speed profile could be applied on velocity mode, position mode in one axis or multi-axes linear interpolation and two axes circular interpolation modes.

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4.2.5 Velocity mode

Veloctiy mode means the pulse command is continuously outputing until a stop command is issued. The motor will run without a target position or desired distance unless it is stopped by other reasons. The output pulse accelerates from a starting velocity to a specified maximum velocity. It can be follow a linear or S-curve acceleration shape. The pulse output rate is kept at maximum velocity until another velocity command is set or a stop command is issued. The velocity could be overrided by a new speed setting. Notice that the new speed could not be a reversed speed of original running speed. The speed profile of this kind of motion is shown as below:

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4.2.6 One axis position mode

Position mode means the motion controller will output a specific amount of pulses which is equal to users’ desired position or distance. The unit of distance or position is pulse internally on the motion controller. The minimum length of distance is one pulse. However, in PCI-8154, we provide a floating point function for users to transform a physical length to pulses. Inside our software library, we will keep those distance less than one pulse in register and apply them to the next motion function. Besides positioning via pulse counts, our motion controller provides three types of speed profile to accomplish positioning. There are 1st order trapezoidal, 2nd order S-curve, and mixed bell curve. Users can call respective functions to perform that. The following char shows the relationship between distance and speed profile. We use trapezoidal shape to show it.

The distance is the area of the V-t diagram of this profile.

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4.2.7 Two axes linear interpolation position mode

“Interpolation between multi-axes” means these axes start simultaneously, and reach their ending points at the same time. Linear means the ratio of speed of every axis is a constant value. Assume that we run a motion from (0,0) to (10,4). The linear interpolation results are shown as below.

The pulses output from X or Y axis remains 1/2 pulse difference according to a perfect linear line. The precision of linear interpolation is shown as below:

If users want to stop an interpolation group, just call a stop function on first axis of the group.

As in the diagram below, 4-axis linear interpo lation means to move the XY position from P0 to P1. The 2 axes start and stop simultaneously, and the path is a straight line.

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The speed ratio along X-axis and Y-axis is (ΔX: ΔY), respectively, and the vector speed is:

When calling 4-axis linear interpolation functions, the ve ctor speed needs to define the start velocity, StrVel, and maximum velocity, MaxVel.

4.2.8 Two axes circular interpolation mode

Circular interpolation means XY axes simultaneously start from initial point, (0,0) and stop at end point, (1800,600). The path between them is an arc, and the MaxVel is the tangential speed. Notice that if the end point of arc is not at a proper position, it will move circularly without stopping.

(1800,600)

(0,0)

Center

(1000,0)

The motion controller will move to the final point user desired even this point is not on the path of arc. But if the final point is not at the location of the shadow area of the following graph, it will run circularly without stopping.

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The command precision of circular interpolation is shown below. The precision range is at radius ±1/2 pulse.

4.2.9 Continuous motion

Continuous motion means a series of motion command or po sition can be run continuously. Users can set a new command right after previous one without interrupting it. The motion controller can make it possible because there are three command buffers (preregisters) inside.

When first command is executing, users can set second command into first buffer and third command into second buffer. Once the first command is finished, the motion controller will push the second command to the executing register and the third command to first buffer. Now, the second buffer is empty and user can set the 4th command into 2nd buffer. Normally, if users have enough time

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to set a new command into 2nd buffer before executing register is finished, the motion can run endlessly. The following diagram shows this architecture of continuous motion.

Besides position command, the speed command should be set correctly to perform a speed continuous profile. For the following example, there are three motion command of this continuous motion. The second one has high speed than the others. The interconnection of speed between these three motion functions should be set as the following diagram:

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If the 2nd command’s speed value is lower than the others, the settings would be like as following diagram:

For 4-axis continuous arc interpolation is the same concept. You can set the speed matched between two command speed settings.

If the INP checking is enabled, the motion will have some delayed between each command in buffers. INP check enabled make the desired point be reached but reduce the smoothing between each command. If users don’t need this delay and need the smoothing, please turn INP checking off.

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4.2.10 Home Return Mode

Home return means searching a zero position point on the coordinate. Sometimes, users use a ORG, EZ or EL pin as a zero position on the coordinate. At the beginning of machine power on, the program needs to find a zero point of this machine. Our motion controller provides a home return mode to make it.

We have many home modes and each mode contents many control phases. All of these phases are done by ASIC. No software efforts or CPU loading will be taken. After home return is finished, the target counter will be reset to zero at the desired condition of home mode. For example, a raising edge when ORG input. Sometimes, the motion controller will still output pulses to make machine show down after resetting the counter. When the motor stops, the counter may not be at zero po int but the home return procedure is finished. The counter value you see is a reference position from machine’s zero point already.

The following figures show the various home modes: R means counter reset ( command and position counter ). E means ERC signal output.

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Home mode=0: ( ORG Turn ON then reset counter )

X When SD is not installed

X When SD is installed and SD is not latched

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Home mode=1: (Twice ORG turn ON then reset counter)

Home mode=2: (ORG ON then Slow down to count EZ numbers and reset counter)

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Home mode=3: (ORG ON then count EZ numbers and reset counter)

Home mode=4: (ORG On then reverse to count EZ number and reset counter)

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Home mode=5: (ORG On then reverse to count EZ number and reset counter, not using FA Speed)

Home mode=6: (EL On then reverse to leave EL and reset counter)

Home mode=7: (EL On then reverse to count EZ number and reset counter)

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Home mode=8: (EL On then reverse to count EZ number and reset counter, not using FA Speed)

Home mode=9: (ORG On then reverse to zero position, an extension from mode 0)

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Home mode=10: (ORG On then counter EZ and reverse to zero position, an extension from mode 3)

Home mode=11: (ORG On then reverse to counter EZ and reverse to zero position, an extension from mode 5)

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Home mode=12: (EL On then reverse to count EZ numbe r a nd reverse to zero position, an extension from mode 8)

4.2.11 Home Search Function

This mode is used to add auto searching function on normal home return mode described in previous section no matter which position the axis is. The following diagram is shown the example for home mode 2 via home search fu nction. The OR G offset can’t be zero. Suggested value is the double length of ORG area.

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4.2.12 Manual Pulser Function

Manual pulser is a device to generate pulse trains by hand. The pulses are sent to motion controller and re-directed to pulse outp ut pins. The input pulses could be multiplied or divided before sending out.

The motion controller receives two kinds of pulse trains from manual pulser device: CW/CCW and AB phase. If the AB phase input mode is selected, the multiplier has additional selection of 1, 2, or

4. The following figure shows pulser ratio block diagram.

4.2.13 Simultaneous Start Function

Simultaneous motion means more than one axis can be starte d by a Simultaneous signal which could be external or internal signals. For external signal, users must set move parameters first for all axes then these axes will wait an extern start/stop command to start or stop. For internal signal, the start command could be from a software start function. Once it is issued, all axes which are in waiting synchronous mode will start at the same time.

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4.2.14 Speed Override Function

Speed override means that users can change command’s speed during the operation of motion. The change parameter is a percentage of original defined speed. Users can define a 100% sp eed value then change the speed by percentage of original speed when motion is running. If users didn’t define the 100% speed value. The default 100% speed is the latest motion command’s maximum speed. This function can be applied on any motion function. If the running motion is S-curve or bell curve, the speed override will be a pure s-curve. If the running motion is t-curve, the speed override will be a t-curve.

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4.2.15 Position Override Function

Position override means that when users issue a positioning command and want to change its target position during this operation. If the new target position is behind current position when override command is issued, the motor will slow down then reverse to new target position. If the new target position is far away from current position on the same direction, the motion will remain its speed and run to new target position. If the override timing is on the deceleration of current motion and the target position is far away from current position on the same direction, it will accelerate to original speed and run to new target position. The operation examples are shown as below. Notice that if the new target position’s relative pulses are smaller than original slow down pulses, this function can’t work properly.

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4.3 The motor driver interface

We provide several dedicated I/Os which can be connected to motor driver directly and have their own functions. Motor drivers have many kinds of I/O pins for external motion controller to use. We classify them to two groups. One is pulse I/O signals including pulse command and encoder interface. The other is digital I/O signals including servo ON, alarm, INP, servo ready, alarm reset and emergency stop inputs. The following sections will describe the functions these I/O pins.

4.3.1 Pulse Command Output Interface

The motion controller uses pulse command to control servo/stepper motors via motor drivers. Please set the drivers to position mode which can accept pulse trains as position command. The pulse command consists of two signal pairs. It is defined as OUT and DIR pins on connector. Each signal has two pins as a pair for differential output. There are two signal modes for pulse output command: (1) single pulse output mode (OUT/DIR), and (2) dual pulse output mode (CW/CCW type pulse output). The mode must be the same as motor driver. The modes vs. signal type of OUT and DIR pins are listed in the table below:

Mode Output of OUT pin Output of DIR pin

Dual pulse output

(CW/CCW)

Single pulse output

(OUT/DIR)

Pulse signal in plus

(or CW) direction

Pulse signal Direction signal (level)

Pulse signal in minus

(or CCW) direction

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Single Pulse Output Mode (OUT/DIR Mode)

In this mode, the OUT pin is for outputting command pulse chain. The numbers of OUT pulse represent distance in pulse. The frequency of the OUT pulse represents speed in pulse per second. The DIR signal represents command direction of positive (+) or negative (-). The diagrams below show the output waveform. It is possible to set the polarity of the pulse chain.

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Dual Pulse Output Mode (CW/CCW Mode)

In this mode, the waveform of the OUT and DIR pins represent CW (clockwise) and CCW (counter clockwise) pulse output respectively. The numbers of pulse represent distance in pulse. The frequency of the pulse represents speed in pulse per second. Pulses output from the CW pin makes the motor mo ve in positive direction, whereas pulse output from the CCW pin makes the motor move in negative direction. The following diagram shows the output waveform of positive (+) commands and negative (-) commands.

The command pulses are counted by a 28-bit command counter. The command counter can store a value of total pulses outputting from controller.

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4.3.2 Pulse feedback input interface

Our motion controller provides one 28-bit up/do wn cou nter of each axis for pulse feedback counting. This counter is called position counter. The position counter counts pulses from the EA and EB signal which have plus and minus pins on connector for differential signal inputs. It accepts two kinds of pulse types. One is dual pulses input (CW/CCW mode) and the other is AB phase input. The AB phase input can be multiplied by 1, 2 or 4. Multiply by 4 AB phase mode is the most commonly used in incremental encoder inputs.

For example, if a rotary encoder has 2000 pulses per rotation, then the counter value read from the position counter will be 8000 pulses per rotation when the AB phase is multiplied by four.

If users don’t use encoder for motion controller, the feedback source for this counter must be set as pulse command output or the counter value will always be zero. If it is set as pulse command output, users can get the position counter value from pulse command output counter because the feedback pulses are internal counted from command output pulses.

The following diagrams show these two types of pulse feedback signal.

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Plus and Minus Pulses Input Mode (CW/CCW Mode)

The pattern of pulses in this mode is the same as the Dual Pulse Output Mode in the Pulse Command Output section except that

the input pins are EA and EB. In this mode, pulses from EA pin cause the counter to count up,

whereas EB pin caused the counter to count down.

90° phase difference signals Input Mode (AB phase Mode)

In this mode, the EA signal is a 90° phase leading or lagging in comparison with the EB signal. “Lead” or “lag ” of phas e difference between two signals is caused by the turning direction of the motor. The up/down counter counts up when the phase of EA signal leads the phase of EB signal.

The following diagram shows the waveform.

The index input (EZ) signal is as the zero reference in linear or rotary encoder. The EZ can be used to define the mechanical zero position of the mechanism. The logic of signal must also be set correctly to get correct result.

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4.3.3 In position signal

The in-position signal is an output signal from motor driver. It tells motion controllers a motor has been reached a position within a predefined error. The predefined error value is in-position value. Most motor drivers call it as INP value. After motion controller issues a positioning command, the motion busy status will keep true until the INP signal is ON. Users can disable INP check for motion busy flag. If it is disabled, the motion busy will be FALSE when the pulses command is all sent.

4.3.4 Servo alarm signal

The alarm signal is an output signal from motor driver. It tells motion controller that there has something error inside servo motor or driver. Once the motion controller receives this signal, the pulses command will stop sending and the status of ALM signal will be ON. The reasons of alarm could be servo motor’s over speed, over current, over loaded and so on. Please check motor driver’s manual about the details.

The logic of alarm signal must be set correctly. If the alarm logic’s setting is not the same as motor driver’s setting, the ALM status will be always ON and the pulse command can never be outputted.

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4.3.5 Error clear signal

The ERC signal is an output from the motion controller. It tells motor driver to clear the error counter. The error counter is counted from the difference of command pulses and feedback pulses. The feedback position will always have a delay from the command position. It results in pulse differences between these two positions at any moment. The differences are shown in error counter. Motor driver uses the error counter as a basic control index. The large the error counter value is, the faster the motor speed command will be set. If the error counter is zero, it means that zero motor speed command will be set.

At following four situations, the ERC signal will be outputted automatically from motion controller to motor driver in order to clear error counter at the same time.

1. Home return is complete

2. The end-limit switch is touched

3. An alarm signal is active

4. An emergency stop command is issued

4.3.6 Servo ON/OFF switch

The servo on/off switch is a general digital output signal on motion controller. We define it as SVON pin on the connector. It can be used for switching motor driver’s controlling state. Once it is turned on, the motor will be held because the control loop of driver is active. Be careful that when the axis is vertically installed and the servo signal is turned off, the axis will be in uncontrolled state. It could fall on the ground. Some situations like servo alarm and emergency signal ON will result in the same trouble.

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4.3.7 Servo Ready Signal

The servo ready signal is a general digital input on motion controller. It has no relative purpose to motion controller. Users can connect this signal to motor driver’s RDY signal to check if the motor driver is in ready state. It lets users to check something like the motor driver’s power has been inputted or not. Or users can connect this pin as a general input for other purpose. It doesn’t affect motion control.

4.3.8 Servo alarm reset switch

The servo driver will raise an alarm signal if there is something wrong inside the servo driver. Some alarm situations like servo motor over current, over speed, over loading and so on. Power reset can clear the alarm status but users usually don’t want to power off the servo motor when operating. There is one pin from servo driver for users to reset the alarm status. Ou r motion controller provides one general output pin for each axis. Users can use this pin for resetting servo alarm status.

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4.4 Mechanical switch interface

We provide some dedicated input pins for mechanical switches like original switch (ORG), plus and minus end-limit switch (±EL), slow down switch (SD), positioning start switch (PCS), counter latch switch (LTC), emergency stop input (EMG) and counter clear switch (CLR). These switches’ response time is very short, only a few ASIC clock times. There is no real-time problem when using these signals. All functions are done by motion ASIC. The software can just do nothing and only need to wait the results.

4.4.1 Original or home signal

Our controller provides one original or home signal for each axis. This signal is used for defining zero position of this axis. The logic of this signal must be set properly before doing home procedure. Please refer to home mode section for details.

4.4.2 End-Limit switch signal

The end-limit switches are usually installed on both ending sides of one axis. We must install plus EL at the positive position of the axis and minus EL at the negative position of the axis. These two signals are for safety reason. If they are installed reversely, the protection will be invalid. Once the motor’s moving part touches one of the end-limit signal, the motion controller will stop sending pulses and output an ERC signal. It can prevent machine crash when miss operation.

4.4.3 Slow down switch

The slow down signals are used to force the command pulse to decelerate to the starting velocity when it is active. This signal is used to protect a mechanical moving part under hig h speed movement toward the mechanism’s limit. The SD signal is effective for both plus and minus directions.

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4.4.4 Positioning Start switch

The positioning start switch is used to move a specific position when it is turned on. The function is shown as below.

4.4.5 Counter Clear switch

The counter clear switch is an input signal which makes the counters of motion controller to reset. If users need to reset a counter according to external command, use this pin as controlling source.

4.4.6 Counter Latch switch

The counter latch switch is an input signal which makes counter value to be kept into a register when this input active. If users n eed to know counter value at the active moment of one input, they can connect this pin to catch that.

4.4.7 Emergency stop input

Our motion controller provides a global digital input for emergency situation. Once the input is turned on, our motion controller will stop all axes’ motion immediately to prevent machine’s damage. Usually, users can connect an emergency stop button to this input on their machine. We suggest this input as normal closed type for safety.

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4.5 The Counters

There are four counters for each axis of this motion controller. They are described in this section.

X Command position counter: counts the number of output

pulses

X Feedback position counter: counts the number of input

pulses

X Position error counter: counts the error between command

and feedback pulse numbers.

X General purpose counter: The source can b e con fig ured as

command position, feedback position, manual pulser, or half of ASIC clock.

X Target position recorder: A software-maintained target posi-

tion value of latest motion command.

4.5.1 Command position counter

The command position counter is a 28-bit binary up/down counter. Its input source is the output pulses from the motion co ntroller. It provides the information of the current command position. It is useful for debugging the motion system.

Our motion system is an open loop type. The motor driver receives pulses from motion controller and drive the motor to move. When the driver is not moving, we can check this command counter and see if there is an update value on it. If it is, it means that the pulses have seen sent and the problem could be on the motor driver. Try to check motor driver’s pulse receiving counter when this situation is happened.

The unit of command counter is in pulse. The counter value could be reset by a counter clear signal or home function completion. Users can also use a software command counter setting function to reset it.

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4.5.2 Feedback position counter

The feedback position counter is a 28-bit binary up/down counter. Its input source is the input pulses from the EA/EB pins. It counts the motor position from motor’s encoder output. This counter could be set from a source of command position for an option when no external encoder inputs.

The command output pulses and feedback input pulses will not always be the same ratio in mini-meters. Users must set the ratio if these two pulses are not 1:1.

Because our motion controller is not a closed-loop type, the feedback position counter is just for reference after motion is moving. The position closed-loop is done by servo motor driver. If the servo driver is well tuned and the mechanical parts are well assembled, the total position error will remain in acceptable range after motion command is finished.

4.5.3 Command and Feedback error counter

The command and feedback error counter is used to calculate the error between the command position and the feedback position. The value is calculated from command subtracting feedback position.

If the ratio between command and feedback is not 1:1, the error counter is meaningless.

This counter is a 16-bit binary up/down counter.

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4.5.4 General purpose counter

The source of general purpose counter could be any of the following:

1. Command position output – the same as a command position counter

2. Feedback position input – the same as a feedback position counter

3. Manual Pulser input – Default setting

4. Clock Ticks – Counter from a timer about 9.8MHz

4.5.5 Target position recorder

The target position recorder is used for providing target position information. It is used in continuous motion because motion controller need to know the previous motion command’s target position and current motion command’s target position in order to calculate relative pulses of current command then send results into pre-register. Please check if the target position is the same with current command position before continuous motion; especially after the home and stop functions.

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4.6 The Comparators

There are 5 counter comparators of each axis. Each comparator has dedicated functions. They are:

1. Positive soft end-limit comparator to command counter

2. Negative soft end-limit comparator to command counter

3. Command and feedback error counter comparator

4. General comparator for all counters

5. Trigger comparator for all command and feedback

counters

4.6.1 Soft end-limit comparators

There are two comparators for end-limit function of each axis. We call them for the soft end-limit comparators. One is for plus or positive end-limit and the other is for minus or negative end-limit. The end-limit is to prevent machine crash when over traveling. We can use the soft limit instead of a real end-limit switch. Notice that these two comparators only compare the command position counter. Once the command position is over the limited set inside the positive or negative comparators, it will stop moving as it touches the end-limit switch.

4.6.2 Command and feedback error counter comparators

This comparator is only for command and feedback counter error. Users can use this comparator to check if the error is too big. It can be set a action when this condition is met. The actions include generating interrupt, immediately stop, and deceleration to stop.

4.6.3 General comparator

The general comparator let users to choose the source to compare. It could be chosen from command, feedback position counter, error counter or general counter. The compare methods could be chosen by equal, greater than or less than with directional or directionless. Also the action when condition is met can be chosen from generating interrupt, stop motion or others.

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4.6.4 Trigger comparator

The trigger comparator is much like general comparator. It has an additional function, generating a trigger pulse when condition is met. Once the condition is met, the CMP pin on the connector will output a pulse for specific purpose like triggering a camera to catch picture. Not all of axes have this function. It depends on the existence of CMP pin of the axis. The following diagram shows the application of triggering.

In this application, the table is controlled by the motion command, and the CCD Camera is controlled by CMP pin. When the comp aring position is reached, the pulse will be outputted and the image is captured. This is an on-the-fly imag e capture. If users want to get more images during the motion path, try to set a new comparing point right after previous image is captured . It can achieve continuous image capturing by this method.

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4.7 Other Motion Functions

We provide many other functions on the motion controller. Such as backlash compensation, slip correction, vibration restriction, speed profile calculation and so on. The following sections will describe these functions.

4.7.1 Backlash compensation and slip corrections

The motion controller has backlash and slip correction functions. These functions output the number of command pulses in FA speed. The backlash compensation is performed each time when the direction changes on operation. The slip correction function is performed before a motion command, regardless of the direction. The correction amount of pulses can be set by function library.

4.7.2 Vibration restriction function

The method of vibration restriction of the motion controller is by adding one pulse of reverse direct ion and then one pulse of forward direction shortly after completing a motion command. The timing of these two dummy pulses are shown below: (RT is reverse time and FT is forward time).

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4.7.3 Speed profile calculation function

Our motion function needs several speed parameters from users. Some parameters are conflict in speed profile. For example, if users input a very fast speed profile and a very short distance to motion function, the speed profile is not exist for these parameters. At this situation, motion library will keep the acceleration and deceleration rate. It tries to lower the maximum speed from users automatically to reform a speed profile feasible. The following diagram shows this concept.

Our motion library has a series of functions to know the actual speed profile of the command from users.

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4.8 Interrupt Control

The motion controller can generate an interrupt signal to the host PC. It is much useful for event-driven software applicatio n. Users can use this function _8154_int_control() to enable if disable the interrupt service.

There are three kinds of interrupt sources on PCI-8154. One is motion interrupt source and the other is error interrupt source and another is GPIO interrupt sources. Motion and GPIO interrupt sources can be maskable but error interrupt sources can’t. Motion interrupt sources can be maskable by _8154_set_motion_int_factor(). Its mask bits are shown as following table:

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Motion Interrupt Source Bit Settings

Bit Description

0 Normally Stop 1 Next command in buffer starts

Command pre-register 2 is empty and allow new

command to write 30 4 Acceleration Start 5 Acceleration End 6 Deceleration Start 7 Deceleration End 8 +Soft limit or comparator 1 is ON 9 -Soft limit or comparator 2 is ON

10 Error comparator or comparator 3 is ON

11 General comparator or comparator 4 is ON 12 Trigger comparator or comparator 5 is ON 13 Counter is reset by CLR input 14 Counter is latched by LTC input 15 Counter is latched by ORG Input 16 SD input turns on 17 0 18 0 19 CSTA input or _8154_start_move_all() turns on

20-31 0

Table 4-1: Motion Interrupt Source Bit Settings

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The error interrupt sources are non-maskable but the error number of situation could be get from _8154_wait_error_interrupt()’s return code if it is not timeout.

Error Interrupt return codes

Value Description

0 +Soft Limit is ON and axis is stopped 1 -Soft Limit is ON and axis is stopped 2 Comparator 3 is ON and axis is stopped 3 General Comparator or comparator 4 is ON and axis is stopped 4 Trigger Comparator or comparator 5 is ON and axis is stopped 5 +End Limit is on and axis is stopped 6 -End Limit is on and axis is stopped 7 ALM is happened and axis is stop 8 CSTP is ON or _8154_stop_move_all is on and axis is stopped

9 CEMG is on and axis is stopped 10 SD input is on and axis is slowed down to stop 11 0 12 Interpolation operation error and stop 13 axis is stopped from other axis’s error stop 14 Pulse input buffer overflow and stop 15 Interpolation counter overflow 16 Encoder input signal error but axis is not stopped 17 Pulse input signal error but axis is not stopped

11~31 0

T able 4-2: Error Interrupt return codes

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The steps for using interrupts:

1. Use _8154_int_control(CARD_ID, Enable=1/Disable=0);

2. Set interrupt sources for Event or GPIO interrupts.

3. _8154_set_motion_int_facor(AXIS0, 0x01); // Axis0 normally stop

4. _8154_wait_motion_interrupt(AXIS0, 0x01, 1000) // Wait 1000ms for normally stop interrupt

5. I16 ErrNo=_8154_wait_error_interrupt(AXIS0, 2000); // Wait 2000ms for error interrupts

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4.9 Multiple Card Operation

The motion controller allows more than one card in one system. Since the motion controller is plug-and-play compatible, the base address and IRQ setting of the card are automatically assigned by the PCI BIOS at the beginning of system booting. Users don’t need and can’t change the resource settings.

When multiple cards are applied to a system, the number of card must be noted. The card number depends on the card ID switch setting on the the board. The axis number is depends on the card ID. For example, if three motion controller cards are plugged in to PCI slots, and the corresponding card ID is set, th en th e axis number on each card will be:

Axis No. X Y Z U

Card ID

0 0123 2 891011 3 12 13 14 15

Notice that if there has the same card ID on multiple cards, the function will not work correctly.

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5 MotionCreatorPro

After installing the hardware (Chapters 2 and 3), it is necessary to correctly configure all cards and double check the system before running. This chapter gives guidelines for establishing a control system and manually testing the 8154 cards to verify correct operation. The MotionCreatorPro software provides a simple yet powerful means to setup, configure, test, and debug a motion control system that uses 8154 cards.

Note that MotionCreatorPro is only available for Windows 2000/ XP with a screen resolution higher than 1024x768. Recommended screen resolution is 1024x768. It cannot be executed under the DOS environment.

5.1 Execute MotionCreatorPro

After installing the software drivers for the 8154 in Windows 2000/ XP, the MotionCreatorPro program can be located at <chosen path>\PCI-Motion\MotionCreatorPro. To execute the program, double click on the executable file or use Start>Program Files>PCI-Motion>MotionCreatorPro.

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5.2 About MotionCreatorPro

Before Running MotionCreatorPro, the following issues should be kept in mind.

1. MotionCreatorPro is a prog ram written in VB.NET 2003, and is available only for Windows 2000/XP with a screen resolution higher than 1024x768. It cannot be run under DOS.

2. MotionCreatorPro allows users to save settings and configurations for 8154 cards. Saved configurations will be automatically loaded the next time MotionCreatorPro is executed. Two files, 8154.ini and 8154MC.ini, in the windows root directory are used to save all settings and configurations.

3. To duplicate configurations from one system to another, copy 8154.ini and 8154MC.ini into the windows root directory.

4. If multiple 8154 cards use the same MotionCreatorPro saved configuration files, the DLL function call _8154_config_from_file() can be invoked within a user developed program. This function is available in a DOS environment as well.

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ADLINK PCI-8154 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

List of Tables

List of Figures

1 Introduction

1.1 Features

1.2 Specifications

1.3 Supported Software

1.3.1 Programming Library

1.3.2 MotionCreatorPro

1.4 Available Terminal Board

2 Installation

2.1 Package Contents

2.2 PCI-8154 Outline Drawing

2.3 PCI-8154 Hardware Installation

2.3.1 Hardware configuration

2.3.2 PCI slot selection

2.3.3 Installation Procedures

2.3.4 Troubleshooting4:

2.4 Software Driver Installation

2.5 CN3 Pin Assignments: Main Connector

2.6 K1/K2 Pin Assignments: Simultaneous Start/ Stop

2.7 JP2 to JP9 Jumper Setting for Pulse Output

2.8 SW1 Card Index Selection

2.9 CN4 Manual Pulsar

3 Signal Connections

3.1 Pulse Output Signals OUT and DIR

3.2 Encoder Feedback Signals EA, EB and EZ

3.3 Origin Signal ORG

3.4 End-Limit Signals PEL and MEL

3.5 In-position Signal INP

3.6 Alarm Signal ALM

3.7 Deviation Counter Clear Signal ERC

3.8 General-purpose Signal SVON

3.9 General-purpose Signal RDY

3.10 Multi-Functional output pin: DO/CMP

3.11 Multi-Functional input pin: DI/LTC/SD/PCS/CLR/ EMG

3.12 Pulser Input Signals PA and PB (PCI-8154)

3.13 Simultaneously Start/Stop Signals STA and STP

4 Operation Theory

4.1 Classifications of Motion Controller

4.1.1 Voltage motion control interface

4.1.2 Pulse motion control interface

4.1.3 Network motion control interface

4.1.4 Software real-time motion control kernel

4.1.5 DSP motion control kernel

4.1.6 ASIC motion control kernel

4.1.7 Compare Table of all motion control types

4.1.8 PCI-8154 motion controller type

4.2 Motion Control Modes

4.2.1 Coordinate system

4.2.2 Absolute and relative position move

4.2.3 Trapezoidal speed profile

4.2.4 S-curve and Bell-curve speed profile

4.2.5 Velocity mode

4.2.6 One axis position mode

4.2.7 Two axes linear interpolation position mode

4.2.8 Two axes circular interpolation mode

4.2.9 Continuous motion

4.2.10 Home Return Mode

4.2.11 Home Search Function

4.2.12 Manual Pulser Function

4.2.13 Simultaneous Start Function

4.2.14 Speed Override Function

4.2.15 Position Override Function

4.3 The motor driver interface

4.3.1 Pulse Command Output Interface

4.3.2 Pulse feedback input interface

4.3.3 In position signal

4.3.4 Servo alarm signal

4.3.5 Error clear signal

4.3.6 Servo ON/OFF switch

4.3.7 Servo Ready Signal

4.3.8 Servo alarm reset switch

4.4 Mechanical switch interface

4.4.1 Original or home signal

4.4.2 End-Limit switch signal